Hydro Test Procedure

THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و السإتشارات‬
CONSULTATIONS CO. ‫الفنية‬

General Department of Equipment ‫الدإارة العامة للمعدات‬
……………..
‫بتـــروجـــ‬ ‫قطاع الخإتبارات‬
‫ـــت‬
HYDRO - TEST PROCEDURE

FOR
RAS GARA
10 "NEWOIL PIPE LINE
Client: PETROPEL
REV: 0.0
PTJ PTB
Name Amin Ahmed Reda Ismail
Signature
Date
1 / 18
Website: www.petrojet.com.eg
……………..
‫ـــت‬
TABLE OF CONTENT
1.0 Data Sheet
2.0 Scope
3.0 Specification and Standard
4.0 List of Equipment & Instruments
5.0 Safety Precaution.
6.0 Documentation
7.0 Testing Of Temporary Launcher & Receiver
8.0 Cleaning and Gauging Procedure.
9.0 Flushing & Filling
10.0 Pressurizing
11.0 Dewatering
12.0 Testing Of Valves Room.
.Attachment 13.0
2 / 18
……………..
‫ـــت‬
1.0 DATA SHEET
SECTION : from (k.p0.0) to (k.p18.0 KM)
NOMINAL DIAMETER : 10"
OUT SIDE DIAMETER : 10"
WALL THICKNESS : 12.7 & 15.09 mm
LENGTH : 18.0 KM
MATERIAL GRADE : API 5L X52
VOLUME / KM : 55.6 M3
TOTAL VOLUME : 1000 M3
TEST MEDIUM : WATER
3 / 18
……………..
2.0 SCOPE ‫ـــت‬
This scope covers Ras Gara 10 " new oil pipe line hydrostatic test carried out by
petrojet and consists of:
- Testing of temporary launcher & receiver
- Pipe line cleaning
- Flushing , gauging & filling
- Pressurizing.
- De watering.
- Testing of valve rooms.
5 / 18
……………..
3.0 ‫ـــت‬
SPECIFICATION & STANDARD
This procedure for hydrostatic test written to meet the requirement for
the following specification and standards according to :
- Client Specifications
- ANSI / ASME CODE B 31.4 ( Liqued Transmission & Distribution System )
- PETROJET Procedure
6 / 18
……………..
‫ـــت‬
4.0 LIST OF EQUIPMENT & INSTRUMENTS
Petrojet will supply the following equipment& instruments to execute the work:
4.1 EQUIPMENT
- Air Compressor
- Prime Pump
- Filling Pump
- Pressurizing Pump
- Storage Tank
- High Pressure Hoses
4.2 INSTRUMENTS
- No. Of (2) Pressure Gauge
- No. Of (2) Pressure Recorder
- No. Of (2) Temperature Recorder
- Dead Weight Tester.
7 / 18
……………..
‫ـــت‬
5.0 SAFETY PRECAUTION
ㄱ All personnel involved in testing operation shall wear full safety
including hard hats, safety boots and gloves to be worn by mechanical
operation.
ㄴ The test cabin will be located in a save position approximate 20 mt.
From the pipeline to be tested.
ㄷ Warning signs ( written in both English & Arabic) will be erected
outside the cordoned off area
ㄹ No personnel will be allowed to work within 30 mt of the pipeline
testing operations are in progress.
8 / 18
……………..
‫ـــت‬
6.0 Documentation
All records for temporary launcher & receiver testing, pipe line cleaning, gauging,
pressurizing and any relevant comments will be completed into "test report" submitted
to the client after hydro test completed .
7.0 TESTING OF TEMPORARY TEST HEAD
- After construction of temporary test head it will be filled with fresh water &
tested as one loop for one hour at the same test pressure of the pipe line.
- After the successful test of the temporary test head it will be separated and
loaded with pigs
- The temporary launcher & receiver will be welded at the two ends of the tested
section.
9 / 18
……………..
‫ـــت‬
CLEANING AND GAUGING PROCEDURE 8.0

- The cleaning and gauging of the pipe line shall be started after the
following.
 All welds have been non-destructively tested and accepted.
 All wrapping and insulation has been completed
 Temporary test head shall be installed at both end of section.
- Compressed air at maximum pressure (7bar) shall be used to run Cleaning and
gauging pigs.
Cleaning pig shall be urethane Bi direction pig -
Gauging pigs shall be urethane Bi direction pig with gauging plate, with diameter = 90 -
.% of minimum internal diameter of pipe line

.Gauging plate material shall be soft Aluminum -
,The gauging plate shall be remarked before launching the gauging pig -
:The remark shall include
Gauging plate diameter ‫ و‬Section No, Date thin Signed by Client Rep. And Petrojet
test engineer
.Client Rep. Shall witness the cleaning and gauging operation -
The following records shall be reported in pigging operation registry -
.and shall signed by Client Rep. and Petrojet test engineer (App. 1)
- The number of pig runs.
.The type of the pig -
.The pressure behind the pig during operation -
.Time of launching and receiving the pig -
.Type of material arriving in front of the pig -
The cleaning certificate (App. 2) and gauging certificate (App. 3) shall be -
.signed by Petrojet Rep. and client Rep
……………..
‫ـــت‬
10/18
9.0Flushing & Filling
0 After gauging had been completed to satisfaction of the client , filling will start
ㄱ The volume required to fill the pipe line will be calculated prior of filling
commencement
ㄴ The filling pump will be connected to the pipe line
ㄷ 20 cubic meter of water will be inserted to the pipe line as flushing water.
ㄹ The filling pig will be launched, and filling will be continued till the pig arrival at
pig receiver then the filling pump will stopped. The line is now completely filled with
water.
ㅁ To ensure that the pipe line is free from the air entrapped, venting will be carried
out several times from launcher and receiver.
……………..
‫ـــت‬ 11/ 18
10.0 PRESSURIZING
ㅂ Check that the pipe line has been completely back filled
ㅅ Check that all temporary fitting has been removed.
ㅇ Check that all instruments has calibration certificate and approved by the client.
ㅈ Pressure pump and instruments at both ends of pipe line will be connected at safe
distance.
ㅊ All fitting, hoses, and valves used during pressurizing pressure which exceeds the
max test pressure applied on pipe line.
ㅋ All charts which used in recorders will be signed by client representative before
pressurizing commencement.
ㅌ Pressurizing will be commencement at static head pressure.
ㅍ Pressure will raised gradually with suitable rate to prevent sudden stress to pipe
line
ㅎ Pressurizing will be stopped at 80% of test pressure for one hour & visual check
will be carried out.
ㄱ Pressurizing will be commencement again to 100% test pressure.
ㄴ Pressure will be hold for 24 hour
ㄷ Pressure will be beaded gradually to static pressure or as client requirement
ㄹ At the end of the test cycle, all sheets & test certificate will be submitted to client
representative for sign and approval.
……………..
12/18
‫ـــت‬
11.0 DE WATERING
After successful test, the pipe line will be cleaned from test water applying compressed
air and the pig will be pushed through the pipe line using compressed air.
12.0 TESTING OF VALVE ROOMS
If the valve room is not available for testing with the pipe line it will be pressure tested
separately as a loop for two hour at the same test pressure of the pipe line.
13/ 18
……………..
‫ـــت‬
13.0 ATTACHMENTS
PIGGING OPERATION REGISTER
Wall thickness: ………mm Nominal diameter: ………..Inch
.………… :Grade
…… :Section From: …… To
Pig type
Inspected & Location
loaded
Date
Time
Location
Launched Date
Time
Pressure
Location
Received Date
Time
Pressure
Location
Inspected Date
Time
Condition
.Petrojet Test Eng .Client Rep
.Name .Name
Sign Sign
Date Date
Appendix (1)
14/18
……………..
‫ـــت‬
GAUGE PLATE ACCEPTANCE CERTIFICATE
/ / :Date
:Project
:Client
SECTION ADTA
……………… :From: ………… To
.Length: ……….Km
.Outside diameter: ………..mm
.Internal Diameter: ……… mm
.Wall thickness: …………..mm
..………… :Grade
.Gauge Plate Diameter. : ………..mm
……………: .Gauge Plate Material
.Name .Name
Sign Sign
Date Date
Appendix (3)
15/18
……………..
‫ت‬
CLEANING ‫ـــ‬
ACCEPTANCE CERTIFICATE
/ / :Date
:Project
:Client
SECTION ADTA
……………… :From: ………… To
.Outside diameter: ………..mm
.Internal Diameter: ……… mm
.Wall thickness: …………..mm
..………… :Grade
THE ABOVE MENTIONED SECTION HAS BEEN CLEANED
.ACCORDING TO
 CLIENT SPESIFICATION.
 HYDROTEST PROCEDURE.
 SATISFACTION OF CLIENT REP.
.Name .Name
Sign Sign
Date Date
Appendix (2)
16/18
……………..
‫ ـــت‬TEST CERTIFICATE
ACCEPTANCE
/ / :Date
:Project
:Client
: Test Section Data
……… :.Test section No
.……………… :from To: ……………
.………… :Pipe Material Grade Length: ………………
Wall Thickness: ……………….mm Nominal Diameter: ……………Inch
Was Tested AS Out Lined Below

:Test Medium
:Test Pressure
TIME DATE PRESSURE .TEMP

FROM
TO
.………………………… :.Dead Wight Serial No

.…………………… :.Pressure Recorder Serial No
..……………… :.Temperature Recorder Serial No
.This test is completed with successful result and accepted
.Name .Name
Sign Sign
Date Date
Appendix (4)
17/18
……………..
‫ت‬ACCEPTANCE
DEWATERING ‫ـــ‬ CERTIFICATE
:Date
:Project
:Client
SECTION ADTA
……………… :From: ………… To
.Outside diameter: ……… mm
.Internal diameter: ……… mm
.Wall thickness: ………….mm
..………… :Grade
THE ABOVE MENTIONED SECTION HAS BEEN DEWATERED
.FROM WATER ACCORDING TO
 CLIENT SPESIFICATION.
 HYDROTEST PROCEDURE.
 SATISFACTION OF CLIENT REP.
.Name .Name
Sign Sign
Date Date
Appendix (5)
18/18

Hydro Test Procedure

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THE PETROLEUM PROJECTS & TECHNICAL ‫شركة المشروعات البترولية و السإتشارات‬

CONSULTATIONS CO. ‫الفنية‬

HYDRO - TEST PROCEDURE

1.0 Data Sheet

3.0 Specification and Standard

4.0 List of Equipment & Instruments

5.0 Safety Precaution.

7.0 Testing Of Temporary Launcher & Receiver

8.0 Cleaning and Gauging Procedure.

9.0 Flushing & Filling

12.0 Testing Of Valves Room.

NOMINAL DIAMETER : 10"

OUT SIDE DIAMETER : 10"

WALL THICKNESS : 12.7 & 15.09 mm

MATERIAL GRADE : API 5L X52

TOTAL VOLUME : 1000 M3

TEST MEDIUM : WATER

petrojet and consists of:

- Testing of temporary launcher & receiver

- Pipe line cleaning

- Flushing , gauging & filling

- Testing of valve rooms.

the following specification and standards according to :

- ANSI / ASME CODE B 31.4 ( Liqued Transmission & Distribution System )

ㄱ All personnel involved in testing operation shall wear full safety

including hard hats, safety boots and gloves to be worn by mechanical

ㄴ The test cabin will be located in a save position approximate 20 mt.

From the pipeline to be tested.

ㄷ Warning signs ( written in both English & Arabic) will be erected

outside the cordoned off area

ㄹ No personnel will be allowed to work within 30 mt of the pipeline

testing operations are in progress.

to the client after hydro test completed .

7.0 TESTING OF TEMPORARY TEST HEAD

loaded with pigs

CLEANING AND GAUGING PROCEDURE 8.0

.% of minimum internal diameter of pipe line

The following records shall be reported in pigging operation registry -

.The pressure behind the pig during operation -

.Time of launching and receiving the pig -

.Type of material arriving in front of the pig -

The cleaning certificate (App. 2) and gauging certificate (App. 3) shall be -

.signed by Petrojet Rep. and client Rep

9.0Flushing & Filling

12.0 TESTING OF VALVE ROOMS

.Petrojet Test Eng .Client Rep

.Petrojet Test Eng .Client Rep

Was Tested AS Out Lined Below

TIME DATE PRESSURE .TEMP

.………………………… :.Dead Wight Serial No

.This test is completed with successful result and accepted

.Petrojet Test Eng .Client Rep

.Petrojet Test Eng .Client Rep

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